Electrode sandwich separation

Abstract

Materials bonded together are separated using electrical current, thermal stresses, mechanical force, any combination of the above methods, or any other application or removal of energy until the bonds disappear and the materials are separated. In one embodiment the original bonding was composed of two layers of material. In another embodiment, the sandwich was composed of three layers. In a further embodiment, the parts of the sandwich are firmly maintained in their respective positions during the application of current so as to be able to subsequently align the materials relative to one another.

1. A method for manufacturing a pair of matching electrodes, said method comprising the steps of:
 a) providing a first electrode; 
 b) placing a material over said first electrode, wherein said material comprises a material that is suitable for use as a second electrode, whereby a composite is formed; and 
 c) separating the composite along a boundary between said first electrode and said second material. 
 
     
     
       2. The method of  claim 1  wherein said step of separating the composite comprises applying an electric current between said first electrode and said material. 
     
     
       3. The method of  claim 1  wherein said step of separating the composite comprises heating said composite. 
     
     
       4. The method of  claim 3 , wherein said heating step comprises heating the composite to a temperature of 40° C. or more. 
     
     
       5. The method of  claim 1  wherein said step of separating the composite comprises cooling said composite. 
     
     
       6. The method of  claim 5 , wherein said cooling step comprises cooling the composite to a temperature of 0° C. or less. 
     
     
       7. The method of  claim 1  wherein said step of separating the composite comprises applying or removing energy to or from the composite. 
     
     
       8. The method of  claim 7  wherein said step of applying energy comprises exposing the composite to an ultrasonic energy source. 
     
     
       9. The method of  claim 1  wherein said step of separating the composite comprises applying a mechanical force. 
     
     
       10. The method of  claim 1  wherein said first electrode comprises titanium. 
     
     
       11. The method of  claim 1  wherein said material comprises silver. 
     
     
       12. The method of  claim 1 , further comprising the steps of:
 a) attaching said first electrode or said material to one or more actuators; and 
 b) using said actuator to apply a mechanical force, thereby separating said composite. 
 
     
     
       13. The method of  claim 1 , further comprising the steps of:
 a) attaching said first electrode or said material to one or more actuators; and 
 b) using said actuator to maintain a region between said first and second electrodes after said separating step, wherein topographical features on the surface of said first electrode are maintained in spatial orientation with a matching topographical feature on said second electrode. 
 
     
     
       14. The method of  claim 1 , wherein said step of separating the composite comprises using any combination of the following methods:
 a) applying an electrical current to the composite; 
 b) cooling the composite; 
 c) heating the composite; and 
 d) forcibly separating the composite.